Skylight roof assembly

ABSTRACT

A skylight roof assembly and method of construction of the roof assembly away from a roof, and when completed the roof assembly is lifted onto an opening cut into the roof, thereby minimizing the amount of time an opening exists in the roof to avoid water damage. The skylight roof assembly comprises a base frame having a plurality of skylight windows generally ranging from two to four. Ice and water shield covers a top surface of the base frame and step flashing surrounds each skylight window. Roof shingles are attached over the ice and water shield and the step flashing. Each skylight window comprises polycarbonate window panels which are mounted on an angled base frame of the skylight roof assembly for efficient water flow away from the skylight window and also to minimize ice build up on the skylight window. Alternate embodiments of the skylight roof assembly include skylight windows of varying sizes and a base frame having an incline greater than the pitch of the roof on which it is located.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to roof skylights and in particular to a method of constructing a skylight roof assembly, having a plurality of skylights, away from a roof and cutting an opening in the roof to receive the completed skylight roof assembly immediately after the roof opening is available, thereby minimizing any opportunity for water leakage and resulting damage inside a residence.

2. Description of Related Art

The placement of skylights in roofs of various slopes has often resulted in water leakage problems. In some roofs there may be very little slope resulting in a tendency for standing water to build up on top of the skylight and eventually result in leakage problems around the skylight. In addition, a skylight may be located under the overhang of an upper roof as in a condominium complex, and in the winter time icicles may form on the edge of the upper roof and eventually drop on the lower roof skylight causing damage to the glass in the skylight or damage to the frame or sealing materials around the skylight resulting in water leakage problems. Many skylights are not easy to repair or replace, and when repaired the same problems will often occur again. Other skylight window problems result from being installed for a period of time and being exposed to a wide variation of weather conditions and being subjected to expansions and contractions due to substantial changes in temperature.

U.S. Pat. No. 4,549,379 issued to Walter S. Loy et al. discloses a curb unit for installation within a rectangular opening formed within a roof deck or sheeting for a single skylight. The curb unit may be constructed by vacuum—forming a sheet of thermoplastics material with an outwardly projecting integral peripheral flange or flashing portion. A skylight is mounted on the curb and may be dome-shaped for dispersing rain water to the edges of the skylight. However, the simple skylight is directly constructed on the roof and not away from it.

U.S. patent RE 33,720 issued to Peter A. Cummings describes a skylight assembly for a sloping roof of a building structure wherein water is channeled to the center of the panel as a result of its concave shape and will flow down the center of the panel to be deposited on the shingles. A hole is cut in the roof for mounting the skylight roof assembly of a size and shape that complements the skylight casing, and framing of the hole is performed followed by inserting the skylight frame into the hole. However, the skylight is installed on a main roof and not constructed as a plurality of skylights in a separate assembly.

U.S. Pat. No. 6,052,956 issued to Walter S. Hoy et al. discloses a skylight assembly mounted within a sloping roof having a sheet of light transmitting polycarbonate for a lower pane and forming an integrally connected curb portion 22, and an upper pane 55 of glass or plastic is attached to the curb portion 22. It is noted that it is common to construct wood rectangular, frame-like curb which projects upwardly from a sloping roof deck. However, it does not teach the method of constructing a skylight roof assembly comprising a plurality of skylights away from a roof on which it is to be installed.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a method of constructing a skylight roof assembly away from a roof on which it is to be installed to minimize the time the roof is cut open to perform the complete installation of the roof assembly.

It is another object of the invention to provide a rugged skylight roof assembly comprising a plurality of skylight windows sufficient to withstand falling icicles from an edge of another roof above the skylight roof assembly.

It is a further object of the invention to provide a skylight roof assembly employing a plurality of skylight windows that enhances a room of a home producing a greenhouse effect.

It is yet another object of the invention to provide a plurality of varying size skylight windows on a roof base having an incline greater than the pitch of a roof on which the inclined skylight assembly is located.

These and other objects are accomplished by a method for making a skylight roof assembly comprising the steps of forming a base frame having a plurality of openings on a top surface, a top edge of the base frame being higher than a bottom edge to provide a predetermined pitch, securing a skylight window in each opening on the top surface of the base frame, applying an ice and water shield to the top surface of the base frame around each skylight window, attaching step flashing to the base frame around the perimeter of each skylight window, an upper first surface of the step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with the ice and water shield, and attaching roof materials over the ice and water shield and over the step flashing in contact with the ice and water shield. The step of inserting a skylight window in each opening of the base frame comprises the step of providing a polycarbonate translucent panel in each skylight window. The step of forming a base and providing a predetermined pitch comprises the step of providing for efficient water flow away from the skylights to minimize a possibility of ice build-up and water leakage. The step of forming the base frame comprises the steps of building a perimeter border with boards approximately two inches by ten-twelve inches, forming each of the plurality of openings to a size for receiving one skylight window, and installing wood sheathing over the border boards and around the plurality of openings to form the top surface of the base frame.

The objects are further accomplished by a method for installing a skylight roof assembly on a roof comprising the steps of forming a base frame having a plurality of openings on a top surface, a top edge of the base frame being higher than a bottom edge to provide a predetermined incline, inserting a skylight window in each opening of the base frame, applying an ice and water shield to the top surface of the base frame around each skylight window, attaching step flashing to the base frame around the perimeter of each skylight window, an upper first surface of the step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with the ice and water shield, attaching roof materials over the ice and water shield and the step flashing in contact with the ice and water shield, cutting on opening in the roof to which the skylight roof assembly is being attached, lifting the skylight roof assembly and placing it on the opening in the roof, and securing the skylight roof assembly to the roof over the opening. The method comprises the step of finishing the inside portion of the skylight roof assembly to provide a pleasant inside appearance. The step of inserting a skylight window in each of the openings comprises the step of providing a polycarbonate translucent panel in each skylight window. The method comprises the step of forming a base frame having a predetermined incline and thereby providing for efficient water flow away from each skylight window to minimize possibility of ice build-up and water leakage. The step of forming the base frame comprises the steps of building a perimeter border with boards approximately two inches by ten-twelve inches, forming each of said plurality of openings to a size for receiving the skylight window, and installing wood sheathing over the border boards and around the plurality of openings to form the top surface of the base frame.

The objects are further accomplished by providing a skylight roof assembly comprising a base frame having a plurality of openings on a top surface, a top edge of the base frame being higher than a bottom edge to provide a predetermined pitch, a skylight window inserted in each opening of the base frame, the base frame comprises a perimeter boarder to raise the skylight windows a predetermined distance above a bottom surface of the base frame, an ice and water shield attached to the top surface of the base frame around each skylight window, and roofing materials attached over the ice and water shield. The base frame comprises step flashing attached to the base frame around the perimeter of each skylight window, an upper first surface of the step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with the ice and water shield. The skylight window in each opening of the base frame comprises a polycarbonate translucent panel. The base frame comprises a predetermined incline for efficient water flow away from the skylights to minimize possibility of ice build-up and water leakage. The perimeter border of the base frame comprises boards approximately two inches by ten-twelve inches, each of the plurality of openings being formed to a size for receiving one skylight window, and the base frame comprises wood sheathing attached over the border boards and around the plurality of openings to form a top surface of the base frame. The skylight roof assembly having a plurality of skylight windows enhances the lighting in a home or building producing a greenhouse effect.

The objects are further accomplished by providing An inclined skylight assembly comprising an inclined roof base having a plurality of openings on a top surface, a top edge of the base being higher than a bottom edge to provide a predetermined pitch, the bottom edge forming a roof line, a rear wall supports a top portion of the inclined roof base, the rear wall extending between a first triangular end section and a second triangular end section, a plurality of skylight windows, each of the skylight windows inserted into a respective opening of the inclined roof base, each opening of the inclined roof base comprises framing three sides extending a predetermined distance below each opening, an ice and water shield attached to the top surface of the included roof base, and roofing materials attached over the ice and water shield. The inclined skylight assembly comprises step flashing attached around the outside perimeter of each skylight window. The rear wall supports the top portion of the inclined roof base forming approximately a ninety degree angle with the roof base. Each of the skylight windows comprises a polycarbonate translucent panel. At least one of the plurality of skylight windows is smaller in size than the other skylight windows mounted in the inclined skylight assembly.

Additional objects, features and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The appended claims particularly point out and distinctly claim the subject matter of this invention. The various objects, advantages and novel features of this invention will be more fully apparent from a reading of the following detailed description in conjunction with the accompanying drawings in which like reference numerals refer to like parts, and in which:

FIG. 1 is a front perspective view of a skylight roof assembly positioned on a roof according to the present invention.

FIG. 2 is an exploded perspective view of the skylight roof assembly showing the base frame with a plurality of openings, ice and water shield covering the upper surface of the base frame, three skylight windows, step flashing around the sides of three skylight windows, and roofing shingles covering the upper surface of the base frame around each of the skylight windows.

FIG. 3 is a front perspective view of the base frame of the skylight roof assembly.

FIG. 4 is a side elevation view of the skylight roof assembly showing a predetermined pitch of the base frame for the skylight roof assembly.

FIG. 5 is a front elevation view of an alternate embodiment of the present invention showing an inclined skylight assembly constructed on a relatively narrow low pitched roof.

FIG. 6 is a side elevation view of the inclined skylight assembly of FIG. 5.

FIG. 7 is an inside bottom perspective view of a major portion of the inclined skylight assembly of FIG. 5 showing three skylight windows and supporting structure.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, a skylight roof assembly 10 having a raised roof 22 is shown installed on a roof 11 of a building. In some buildings an upper roof (not shown) may overhang above the skylight roof assembly 10. The method of making or constructing the skylight roof assembly 10 is accomplished away from the roof 11 on which it will be installed in an area generally protected from the weather. However, for a smaller roof assembly, it may be more efficient to construct the skylight roof assembly having a raised roof in place on the roof. The method is particularly useful for an existing roof 11 where it is highly desirable not to have an opening made in the roof until the skylight roof assembly 10 is constructed and ready to be installed on roof 11. The roof 11 may include an existing roof on a building, a plurality of existing skylights which may have become defective needing replacement, or a roof of a new building which may have plywood or boards on it.

Referring to FIG. 2 and FIG. 3, FIG. 2 is an exploded perspective view of the skylight roof assembly 10 according to the present invention, and FIG. 3 is a front perspective view of the base frame 12 of the skylight roof assembly 10 generally constructed away from the roof 11 on which it will be installed. The base frame 12 comprises a plurality of openings 14 a, 14 b, 14 c on a top surface, each opening is made to receive a skylight window 16 a, 16 b, 16 c. Ice and water shield 18 is laid onto the top surface of the base frame 12 around the three skylight windows 16 a, 16 b, 16 c. The number of skylight windows is three in the present embodiment, however, there may be two to four or more, depending on roof space availability. The base frame 12 comprises a perimeter border 15 a, 15 b, 15 c, 15 d to raise the skylight windows 16 a, 16 b, 16 c a predetermined distance 17 above a bottom surface of the base frame 12. The dimensions of each skylight windows 16 a, 16 b, 16 c may vary depending on available space. In order to prevent any water leakage around the skylight windows 16 a, 16 b, 16 c, step flashing 20 is positioned and attached around the perimeter of each skylight windows 16 a, 16 b, 16 c. An upper first surface of the step flashing 20 is in contact with the vertical sides of the skylight windows 16 a, 16 b, 16 c and a lower second surface is in contact with the ice and water shield 18. Roof materials such as shingles 22 or other known roofing materials such as a metal roof are attached over the ice and water shield 18 and the step flashing 20. As shown in FIG. 3, the side borders 15 a, 15 b, 15 c, 15 d of the base frame 12 and the openings 14 a, 14 b and 14 c are constructed with two inch by ten-twelve inch boards and plywood sections to form the upper surface 13.

Referring to FIG. 4, a side elevation view of the base frame 12 of the skylight roof assembly 10 shows a predetermined pitch of the base frame 12 for installation on roof line 30, and when the skylight roof assembly 10 is completed and installed on the roof line 30, the angle of incline provides for run off of water falling on the skylight windows 16 a, 16 b, 16 c. In an alternate embodiment the skylight windows 16 a, 16 b, 16 c may have a greater angle of incline 32 than the pitch of the roof line in order to increase rain and snow run-off and minimize ice build-up. This is accomplished by the addition of a triangular riser section 34 which increases the angle of incline of the base frame 12. The base frame 12 is generally constructed off-line on a plurality of stilts (not shown) to maintain the angle of incline for convenience during the construction phase.

When the weather is suitable and the skylight roof assembly 10 is constructed, the opening is prepared in roof 11 and the skylight roof assembly 10 is picked up by, for example, a forklift or other well-known lifting machines such as a derrick, and positioned on blocks over the opening which enables the forks of the machine to be removed leaving the skylight roof assembly 10 positioned on framing around the edges of the opening and over the opening in the roof. When the blocks are removed the skylight roof assembly moves down into the perimeter framing where it is supported. The inside of the base frame 12 is then finished by sheetrock wall board which is then taped, sanded and painted resulting in an attractive greenhouse-type room within a residence.

In the preferred embodiment as shown in FIG. 3, the base frame 12 is approximately 127 inches wide, 63 inches high and 8.5 inches deep. Each skylight window opening 14 a, 14 b, 14 c is approximately 30 9/16 inches by 30⅜ inches for receiving one of the skylight windows 15 a, 15 b, 15 c which may be embodied by units manufactured by Velux America, Inc. of Greenwood, S.C. Each skylight window comprises a polycarbonate translucent panel.

Referring to FIG. 2, the ice and water shield 18 is commonly available at Home Product Stores. The step flashing 20 may be embodied by a step flashing kit, Model 308, manufactured by EDL of Windsor, Conn. The roof singles 22 may be embodied by any roofing shingle generally matching the shingles on the roof 11 or other commonly known types of roofing materials.

Referring to FIG. 5, a front elevation view is shown of an alternate embodiment of the present invention comprising an inclined skylight assembly 50 constructed on a relatively narrow, low pitched roof 66. The inclined skylight assembly 50 is particularly intended for use on building a house or condominium where skylight windows 60 a, 60 b, 60 c are desired, but must be positioned on an inclined roof 52 which has a greater incline than that of the original low pitch roof 66 to provide faster run-off of rain water and ice. The inclined roof 52 extends from the front edge 56 of the original low pitch roof 66 up to a rear edge 58 adjacent to a rear wall 55 of the building, house or condominium. As shown in FIG. 5, there are two different widths of skylight windows, skylight windows 60 a and 60 c being one width and 60 b being another width in order for the three skylight windows 60 a, 60 b, 60 c to fit within a predetermined allowed space determined by, for example, a wall 75 separating two separately owned condominiums, and also internal walls within the unit receiving the inclined skylight assembly 50. Each skylight window comprises a polycarbonate translucent panel, and it is manufactured by Velux America, Inc. of Greenwood, S.C.

Referring to FIG. 6 and FIG. 7, FIG. 6 is a side elevation view of the inclined skylight assembly 50 of FIG. 5 showing the first skylight window 60 a positioned in roof 52 and extending slightly above the roof 52. FIG. 7 is an inside, bottom perspective view of a major portion of the inclined skylight assembly of FIG. 5 showing the three skylight windows 60 a, 60 b, 60 c and supporting structures including rectangular beams 78, a rear support wall 76 and front wall 80. Under the shingles of the inclined roof 52 is an ice and water shield 62 which rests on a top surface 82 of an inclined roof base 64 which is made of wood sheathing. Step flashing (not shown but similar to the step flashing 20 in FIG. 2) is placed around each of the skylight windows 60 a, 60 b, 60 c. The inclined roof base 64 is a triangular structure comprising three cutouts 68 a, 68 b, 68 c into which the skylight windows 60 a, 60 b, 60 c are mounted. Cutout 68 b is not as wide as cutouts 68 a and 68 c due to space limitations. In other embodiments, the center cutout 68 b may be equal or larger than the end cutouts 68 a and 68 c. FIG. 5 shows the skylight windows 60 a, 60 b and 60 c positioned in cutouts 68 a, 68 b and 68 c respectively. The triangular ends 70, 72 of the inclined roof base 64 may be formed using commonly available wood boards. As shown in FIG. 7, the framing for the cutouts 68 a, 68 b, and 68 c may be formed using commonly available 2 inch×10-12 inch boards, which extend downward between the skylight windows 60 a, 60 b, 60 c and are closed off at the bottom forming rectangular beams 78 on the inside between each skylight window 60 a, 60 b, 60 c. The lower end of the rectangular beam 78 is perpendicular to a small front wall 80 that is parallel to outside wall 55. All of the inside walls 76, 80 and four beams 78 are finished walls that may be plastered or wallboarded and painted. The rear support wall 76 of the inclined roof base 64 is constructed to form an angle 74 of approximately 90° between the wall 76 and the roof 52. The original low pitched roof 66 is shown in FIG. 6 for reference and remains on each side of the inclined skylight assembly 50.

This invention has been disclosed in terms of preferred embodiments depending on a particular application. It will be apparent that many modifications can be made to the disclosed method and apparatus without departing from the invention. Therefore, it is the intent of the appended claims to cover all such variations and modifications as come within the true spirit and scope of this invention. 

1. A method for making a skylight roof assembly comprising the steps of: forming a base frame having a plurality of openings on a top surface, a top edge of the base frame being higher than a bottom edge to provide a predetermined pitch; securing a skylight window in each opening on said top surface of said base frame; applying an ice and water shield to said top surface of said base frame around each skylight window; attaching step flashing to said base frame around the perimeter of each skylight window, an upper first surface of said step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with said ice and water shield; and attaching roof materials over said ice and water shield and over said step flashing in contact with said ice and water shield.
 2. The method as recited in claim 1 wherein said step of inserting a skylight window in each opening of said base frame comprises the step of providing a polycarbonate translucent panel in each skylight window.
 3. The method as recited in claim 1 wherein said step of forming a base and providing a predetermined pitch comprises the step of providing for efficient water flow away from said skylights to minimize a possibility of ice build-up and water leakage.
 4. The method as recited in claim 1 wherein said step of forming said base frame comprises the steps of: building a perimeter border with boards approximately two inches by ten-twelve inches; forming each of said plurality of openings to a size for receiving said skylight window; and installing wood sheathing over said border boards and around said plurality of openings to form said top surface of said base frame.
 5. A method for installing a skylight roof assembly on a roof comprising the steps of: forming a base frame having a plurality of openings on a top surface, a top edge of said base frame being higher than a bottom edge to provide a predetermined incline; inserting a skylight window in each opening of said base frame; applying an ice and water shield to said top surface of said base frame around each skylight window; attaching step flashing to said base frame around the perimeter of each skylight window, an upper first surface of said step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with said ice and water shield; attaching roof materials over said ice and water shield and said step flashing in contact with said ice and water shield; cutting on opening in said roof to which said skylight roof assembly is being attached; lifting said skylight roof assembly and placing it on said opening in said roof; and securing said skylight roof assembly to said roof over said opening.
 6. The method as recited in claim 5 wherein said method comprises the step of sheetrocking and painting an inside portion of said skylight roof assembly to provide a finished inside appearance.
 7. The method as recited in claim 5 wherein said step of inserting a skylight window in each of said openings comprises the step of providing a polycarbonate translucent panel in each skylight window.
 8. The method as recited in claim 5 wherein said method comprises the step of forming a base frame having a predetermined incline wherein said step provides for efficient water flow away from each skylight window to minimize possibility of ice build-up and water leakage.
 9. The method as recited in claim 5 wherein said step of forming said base frame comprises the steps of: building a perimeter border with boards approximately two inches by ten-twelve inches; forming each of said plurality of openings to a size for receiving said skylight window; and installing wood sheathing over said border boards and around said plurality of openings to form said top surface of said base frame.
 10. A skylight roof assembly comprising: a base frame having a plurality of openings on a top surface, a top edge of said base frame being higher than a bottom edge to provide a predetermined pitch; a skylight window inserted in each opening of said base frame; said base frame comprises a perimeter boarder to raise said skylight windows a predetermined distance above a bottom surface of said base frame; an ice and water shield attached to said top surface of said base frame around each skylight window; and roofing materials attached over said ice and water shield.
 11. The skylight assembly as recited in claim 10 wherein: said base frame comprises step flashing attached to said base frame around the perimeter of each skylight window, an upper first surface of said step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with said ice and water shield.
 12. The skylight roof assembly as recited in claim 10 wherein said skylight window in each opening of said base frame comprises a polycarbonate translucent panel.
 13. The skylight roof assembly as recited in claim 10 wherein said base frame comprises a predetermined incline for efficient water flow away from said skylights to minimize possibility of ice build-up and water leakage.
 14. The skylight roof assembly as recited in claim 10 wherein said perimeter border of said base frame comprises boards approximately two inches by ten-twelve inches; each of said plurality of openings being formed to a size for receiving one skylight window; and said base frame comprises wood sheathing attached over said border boards and around said plurality of openings to form a top surface of said base frame.
 15. The skylight roof assembly as recited in claim 10 wherein said skylight roof assembly having a plurality of skylight windows enhances the lighting in a home or building producing a greenhouse effect.
 16. A skylight roof assembly for installing on a roof comprising: a base frame having a plurality of openings on a top surface, a top edge of said base frame being higher than a bottom edge to provide a predetermined incline; a skylight window inserted in each opening of said base frame; said base frame comprises a perimeter boarder to raise said skylight windows a predetermined distance above a bottom surface of said base frame; an ice and water shield attached to said top surface of said base frame around each skylight window; roofing materials attached over said ice and water shield; an opening cut in said roof to which said skylight roof assembly is being attached; means for lifting said skylight roof assembly and placing said skylight roof assembly on said opening in said roof; and means for securing said skylight roof assembly to said roof over said opening.
 17. The skylight roof assembly as recited in claim 16 wherein: said base frame comprises step flashing attached to said base frame around the perimeter of each skylight window, an upper first surface of said step flashing being in contact with the sides of each skylight window and a lower second surface being in contact with said ice and water shield.
 18. The skylight roof assembly as recited in claim 16 wherein said skylight roof assembly comprises an inside portion which is finished to have an attractive inside appearance.
 19. The skylight roof assembly as recited in claim 16 wherein each skylight window in each of said openings comprises a polycarbonate translucent panel.
 20. The skylight roof assembly as recited in claim 16 wherein said base frame comprises a predetermined incline for efficient water flow away from each skylight window to minimize possibility of ice build-up and water leakage.
 21. The skylight roof assembly as recited in claim 16 wherein said base frame comprises: said perimeter border having boards approximately two inches by ten-twelve inches; a plurality of openings, each of said openings being formed to a size for receiving one skylight window; and wood sheathing installed over said border boards and around said plurality of openings to form said top surface of said base frame.
 22. The skylight roof assembly as recited in claim 16 wherein said skylight roof assembly having a plurality of skylight windows enhances the lighting in a home producing a greenhouse effect.
 23. An inclined skylight assembly comprising: an inclined roof base having a plurality of openings on a top surface, a top edge of said base being higher than a bottom edge to provide a predetermined pitch, said bottom edge forming a roofline; a rear wall supports a top portion of said inclined roof base, said rear wall extending between a first triangular end section and a second triangular end section; a plurality of skylight windows, each of said skylight windows inserted into a respective opening of said inclined roof base; each opening of said inclined roof base comprises framing on three sides extending a predetermined distance below each an ice and water shield attached to said top surface of said included roof base; and roofing materials attached over said ice and water shield.
 24. The inclined skylight assembly as recited in claim 23 wherein said inclined skylight assembly comprises step flashing attached around the outside perimeter of each skylight window.
 25. The inclined skylight assembly as recited in claim 23 wherein said rear wall supports said top portion of said inclined roof base forming approximately a ninety degree angle with said roof base.
 26. The inclined skylight assembly as recited in claim 23 wherein each of said skylight windows comprises a polycarbonate translucent panel.
 27. The inclined skylight assembly as recited in claim 23 wherein at least one of said plurality of skylight windows is smaller in size than the other skylight windows. 